Copolymer, rubber composition, crosslinked rubber composition, and tire

ABSTRACT

Provided is a copolymer of a conjugated diene compound and a non-conjugated olefin, the copolymer being a tapered copolymer including: at least one of a block sequence including monomer units of the conjugated diene compound and a block sequence including monomer units of the non-conjugated olefin; and a random sequence including randomly arranged monomer units of the conjugated diene compound and monomer units of the non-conjugated olefin.

TECHNICAL FIELD

The present invention relates to a copolymer of a conjugated diene compound and a non-conjugated olefin, a rubber composition, a crosslinked rubber composition, and a tire, and more particularly to a tapered copolymer used for manufacturing a rubber excellent in heat resistance and flex fatigue resistance, a rubber composition including the tapered copolymer, a crosslinked rubber composition obtained by crosslinking the rubber composition, and a tire manufactured by using the rubber composition or the crosslinked rubber composition.

BACKGROUND ART

At least two different monomers can be polymerized in the same polymerization system so as to generate a copolymer having those different monomer units arranged as repeating units in one polymer chain, and the copolymer thus obtained can be classified into a random copolymer, an alternating copolymer, a block copolymer, or a graft copolymer, depending on the arrangement of the monomer units. However, no report has been made on the arrangement of monomer units in polymerization reaction of a conjugated diene compound and a non-conjugated olefin.

For example, JP 2000-154210 A (PTL 1) discloses a catalyst for polymerization of a conjugated diene, the catalyst including a group IV transition metal compound which has a cyclopentadiene ring structure, in which an α-olefin such as ethylene is exemplified as a monomer copolymerizable with the conjugated diene. However, no reference is made on the arrangement of monomer units in the copolymer. Further, JP 2006-249442 A (PTL 2) discloses a copolymer of an α-olefin and a conjugated diene compound, but no reference is made on the arrangement of monomer units in the copolymer. Further, JP 2006-503141 A (PTL 3) discloses an ethylene/butadiene copolymer synthesized by using a catalytic system consisting of a specific organometallic complex, but merely describes that the butadiene as a monomer is inserted in the form of trans-1,2-cyclohexane into the copolymer, without making any reference to the arrangement of monomer units in the copolymer. It goes without saying that no reference or indication is made as to the manufacture of a rubber which includes monomer units arranged in a tapered structure in the copolymer to thereby obtain an excellent heat resistance and flex fatigue resistance.

In addition, JP 11-228743 A (PTL 4) discloses an unsaturated elastomer composition composed of an unsaturated olefin-based copolymer and a rubber, but merely describes that monomer units in the copolymer are randomly arranged. It goes without saying that no reference or indication is given as to the manufacture of a rubber which includes monomer units arranged in a tapered structure in the copolymer to thereby obtain an excellent heat resistance and flex fatigue resistance.

CITATION LIST Patent Literature

-   PTL 1: JP 2000-154210 A -   PTL 2: JP 2006-249442 A -   PTL 3: JP 2006-503141 A -   PTL 4: JP 11-228743 A

SUMMARY OF INVENTION Technical Problem

In view of the above, an object of the present invention is to provide: a tapered copolymer of a conjugated diene compound and a non-conjugated olefin, which is used for manufacturing a rubber excellent in heat resistance and flex fatigue resistance; a rubber composition including the tapered copolymer; a crosslinked rubber composition obtained by crosslinking the rubber composition; and a tire manufactured by using the rubber composition or the crosslinked rubber composition.

Solution to Problem

As a result of keen study for solving the aforementioned problems, the inventors of the present invention have found the following, and achieved the present invention. That is, in the case of introducing a conjugated diene compound into a polymerization system for copolymerizing the conjugated diene compound and a non-conjugated olefin, the conjugated diene compound can be introduced in the presence of the non-conjugated olefin so as to control the arrangement of monomer units in the copolymer, to thereby obtain a tapered copolymer.

That is, a copolymer according to the present invention is a copolymer of a conjugated diene compound and a non-conjugated olefin, the copolymer being a tapered copolymer including: at least one of a block sequence including monomer units of the conjugated diene compound and a block sequence including monomer units of the non-conjugated olefin; and a random sequence including randomly arranged monomer units of the conjugated diene compound and monomer units of the non-conjugated olefin.

Here, the tapered copolymer herein refers to a copolymer formed of at least one of a block sequence including monomer units of the conjugated diene compound and a block sequence including monomer units of the non-conjugated olefin (the block sequence also being referred to as block structure), and a random sequence (also referred to as random structure) including randomly arranged monomer units of the conjugated diene compound and monomer units of the non-conjugated olefin. According to the present invention, the block structure refers to a structure including components having an absolute molecular weight of more than 10,000; while the random structure refers to a structure including components having an absolute molecular weight of 10,000 or less. For example, in a case where a copolymer includes: a butadiene unit a having an absolute molecular weight over 10,000; an ethylene unit b having an absolute molecular weight of 3,000; a butadiene unit c having an absolute molecular weight of 2,000; an ethylene unit d having an absolute molecular weight of 5,000; and a butadiene unit e having an absolute molecular weight of 3,000, the units a to e being coupled to one another in the stated order, the block structure refers to the butadiene unit a while the random structure refers to a portion where the ethylene unit b, the butadiene unit c, the ethylene unit d, and the butadiene unit e are coupled to one another.

In other words, the tapered copolymer has a continuous or discontinuous distribution of the composition including a conjugated diene compound component and a non-conjugated olefin component. Here, the non-conjugated olefin component preferably has a chain structure which does not include many of long-chain non-conjugated olefin block components (of high molecular weight: absolute molecular weight of more than 10,000) while including many of short-chain non-conjugated olefin block components (of low molecular weight: absolute molecular weight of less than 10,000).

In the copolymer according to the present invention, a cis-1,4 bond content in the conjugated diene compound unit (unit derived from the conjugated diene compound) is preferably at least 30%, which is more preferably at least 50%.

The content of 1,2 adducts (including 3,4 adducts) in the conjugated diene compound unit (the content of 1,2 adduct units (including 3,4 adduct units) in a unit derived from the conjugated diene compound) is preferably 5% or less.

In another preferred example of the copolymer of the present invention, the non-conjugated olefin (unit derived from the non-conjugated olefin) is contained over 0 mol % to 50 mol % or less. Here, the non-conjugated olefin (unit derived from the non-conjugated olefin) is preferably contained over 0 mol % to 40 mol % or less.

In another preferred example of the copolymer according to the present invention, the tapered copolymer has any one of the structures of (A-B)_(X), A-(B-A)_(X) and B-(A-B)_(X) (where A represents a random sequence including randomly arranged monomer units of the conjugated diene compound and of the non-conjugated olefin, B represents one of a block sequence including monomer units of the conjugated diene compound and a block sequence including monomer units of the non-conjugated olefin, and x represents an integer of at least 1).

The copolymer according to the present invention preferably has a polystyrene-equivalent average-weight molecular weight of 10,000 to 10,000,000.

The copolymer according to the present invention preferably has a molecular weight distribution (Mw/Mn) of 10 or less, which is more preferably 5 or less.

In a preferred example of the copolymer according to the present invention, the non-conjugated olefin is an acyclic olefin.

In another preferred example of the copolymer of the present invention, the non-conjugated olefin has 2 to 10 carbon atoms.

In the copolymer according to the present invention, the non-conjugated olefin is preferably at least one selected from a group consisting of ethylene, propylene, and 1-butene, and the non-conjugated olefin is more preferably ethylene.

In another preferred example of the copolymer according to the present invention, the conjugated diene compound is at least one selected from a group consisting of 1,3-butadiene and isoprene.

A rubber composition according to the present invention includes the copolymer of the present invention.

The rubber composition according to the present invention preferably includes the copolymer in a rubber component.

The rubber composition according to the present invention preferably includes, with respect to 100 parts by mass of the rubber component, a reinforcing filler by 5 parts by mass to 200 parts by mass of, and a crosslinking agent by 0.1 parts by mass to 20 parts by mass.

A crosslinked rubber composition according to the present invention is obtained by crosslinking the rubber composition of the present invention.

A tire according to the present invention is manufactured by using the rubber composition of the present invention or the crosslinked rubber composition of the present invention.

Advantageous Effect of Invention

The present invention is capable of providing: a tapered copolymer of a conjugated diene compound and a non-conjugated olefin, which is used for manufacturing a rubber excellent in heat resistance and flex fatigue resistance; a rubber composition including the tapered copolymer; a crosslinked rubber composition obtained by crosslinking the rubber composition; and a tire manufactured by using the rubber composition or the crosslinked rubber composition.

BRIEF DESCRIPTION OF DRAWINGS

The present invention will be further described below with reference to the accompanying drawings, wherein:

FIG. 1 is a ¹³C-NMR spectrum chart of a copolymer A;

FIG. 2 shows a DSC curve of the copolymer A;

FIG. 3 is a ¹³C-NMR spectrum chart of a copolymer B;

FIG. 4 shows a DSC curve of the copolymer B;

FIG. 5 shows a DSC curve of a copolymer C;

FIG. 6 shows a DSC curve of a copolymer D; and

FIG. 7 shows a DSC curve of a copolymer E.

DESCRIPTION OF EMBODIMENTS

(Copolymer)

The present invention will be described in detail hereinafter. The present invention provides a copolymer of a conjugated diene compound and a non-conjugated olefin copolymer, which is a tapered copolymer including: at least one of a block sequence including monomer units of the conjugated diene compound and a block sequence including monomer units of the non-conjugated olefin; and a random sequence including randomly arranged monomer units of the conjugated diene compound and monomer units of the non-conjugated olefin. The copolymer of the present invention is a tapered copolymer, and thus high in fracture strength by taking advantage of having a block sequence, while benefitting from a random sequence as well.

Here, the random sequence offers benefits by, for example, allowing a non-conjugated olefin with heat resistance property or the like to be introduced into the main chain of the copolymer without causing macrophase separation of the copolymer.

The tapered copolymer to be formed according to the present invention is identified mainly by means of differential scanning calorimetry (DSC) and nuclear magnetic resonance (NMR).

Here, the differential scanning calorimetry (DSC) is a measuring method according to JIS K 7121-1987. Specifically, when the DSC observes a glass transition temperature and a crystallization temperature derived from a block sequence including monomer units of a conjugated diene compound and a crystallization temperature derived from a block sequence including monomer units of a non-conjugated olefin, it means that the copolymer has a block sequence including monomer units of a conjugated diene compound or a block sequence including monomer units of a non-conjugated olefin formed therein. Further, when DSC observes, in addition to the crystallization temperature derived from a block sequence including monomer units of a non-conjugated olefin, a wide peak on the lower temperature region side than the peak of the crystallization temperature, it means that the copolymer has a random sequence including randomly arranged monomer units of the conjugated diene compound and monomer units of the non-conjugated olefin formed therein, in addition to the block sequence (including a block of low molecular weight) including monomer units of a non-conjugated olefin. However, when the crystallization temperature derived from a block sequence including monomer units of a non-conjugated olefin is not observed by DSC, it means that the copolymer has the arrangement which only includes a completely random arrangement of monomer units of a non-conjugated olefin, without including a block sequence of low molecular weight.

The copolymer of the present invention is free of a problem of molecular weight reduction, and the weight-average molecular weight (Mw) thereof is not specifically limited. However, in view of the application to polymer materials, a polystyrene-equivalent weight-average molecular weight (Mw) of the copolymer is preferably 10,000 to 10,000,000, more preferably 10,000 to 1,000,000, and particularly preferably 50,000 to 600,000. Further, the molecular weight distribution (Mw/Mn) obtained as a ratio of the weight-average molecular weight (Mw) to the number average molecular weight (Mn) is preferably 10 or less, and more preferably 5 or less. Here, the average molecular weight and the molecular weight distribution can be determined by gel permeation chromatography (GPC) using polystyrene as a standard reference material.

According to the copolymer of the present invention, the cis-1,4 bond content in the conjugated diene compound unit (unit derived from the conjugated diene compound) is preferably at least 30%, more preferably at least 50%, and particularly preferably at least 75%. The cis-1,4 bond content in the conjugated diene compound unit (unit derived from the conjugated diene compound) is further preferably at least 80%, still further preferably at least 90%, and most preferably at least 95%. The cis-1,4 bond content in the conjugated diene compound unit (unit derived from the conjugated diene compound) of 30% or more allows the glass transition temperature (Tg) to be maintained low, which improves physical property such as wear resistance.

The cis-1,4 bond content corresponds to an amount in a unit derived from the conjugated diene compound, rather than the ratio to the entire copolymer.

According to the copolymer of the present invention, the content of the non-conjugated olefin (unit derived from the non-conjugated olefin) is preferably over 0 mol % to 50 mol % or less, and further preferably over 0 mol % to 40 mol % or less. The content of the non-conjugated olefin (unit derived from the non-conjugated olefin) falling within the ranges specified above is capable of effectively improving heat resistance, without causing macrophase separation of the copolymer.

On the other hand, according to the copolymer of the present invention, the content of the conjugated diene compound (unit derived from the conjugated diene compound) is preferably 50 mol % or more to less than 100 mol %, and further preferably 60 mol % or more to less than 100 mol %. With the content of the conjugated diene compound (unit derived from the conjugated diene compound) falling within the ranges specified above, the copolymer of the present invention is allowed to uniformly behave as an elastomer.

According to the copolymer of the present invention, examples of the structure of the tapered copolymer include (A-B)_(X), A-(B-A)_(X), and B-(A-B)_(X). Here, A represents a random sequence including randomly arranged monomer units of a conjugated diene compound and of a non-conjugated olefin; B represents a block sequence including monomer units of a conjugated diene compound and a block sequence including monomer units of a non-conjugated olefin; and x represents an integer of at least 1. Here, the block sequence also includes a multiblock sequence. Further, a block copolymer including a plurality of structures of (X—Y) or of (Y—X) is referred to as multiblock sequence (in which: X denotes a block sequence including monomer units of a non-conjugated olefin; and Y denotes a block sequence including monomer units of a conjugated diene compound).

A conjugated diene compound to be used as a monomer preferably has 4 to 12 carbon atoms. Specific examples of such conjugated diene compounds include: 1,3-butadiene; isoprene; 1,3-pentadiene; and 2,3-dimethyl butadiene, with the 1,3-butadiene and the isoprene being preferred. These conjugated diene compounds may be used alone or in combination of two or more.

Any of the aforementioned specific examples of conjugated diene compounds can be used for preparing the copolymer of the present invention in the same mechanism.

On the other hand, a non-conjugated olefin to be used as a monomer, which is a non-conjugated olefin other than the conjugated diene compound, has an excellent heat resistance, and is capable of reducing the ratio of double covalent bonds in the main chain of the copolymer so as to reduce crystallinity thereof, to thereby increase design freedom as an elastomer. Further, the non-conjugated olefin is preferably an acyclic olefin, and the non-conjugated olefin preferably has 2 to 10 carbon atoms. Therefore, preferred examples of the aforementioned non-conjugated olefin include α-olefins such as: ethylene; propylene; 1-butene; 1-pentene; 1-hexene; 1-heptene; and 1-octene. Of those, ethylene, propylene, 1-butene are more preferred, and ethylene is particularly preferred. These non-conjugated olefins may be used alone or in combination of two or more. Here, olefin refers to unsaturated aliphatic hydrocarbon, which is a compound containing at least one carbon-carbon double covalent bond.

According to the copolymer of the present invention, the content of 1,2 adducts (including 3,4 adducts) in the conjugated diene compound (the content of 1,2 adduct units (including 3,4 adduct units) of the conjugated diene compound in a unit derived from the conjugated diene compound) is preferably 5% or less, more preferably 2.5% or less, and further preferably 1.0% or less.

When the content of 1,2 adducts (including 3,4 adducts) in the conjugated diene compound (the content of 1,2 adduct units (including 3,4 adduct units) of the conjugated diene compound in a unit derived from the conjugated diene compound) is 5% or less, the copolymer of the present invention can further be improved in heat resistance and flex fatigue resistance.

The content of 1,2 adduct units (including 3,4 adduct units) corresponds to an amount contained in a unit derived from the conjugated diene compound, rather than the ratio to the entire copolymer.

Here, the content of 1,2 adduct units (including 3,4 adduct units) in the conjugated diene compound unit (the content of 1,2 adduct units (including 3,4 adduct units) of a conjugated diene compound in a unit derived from the conjugated diene compound) is equal to a 1,2-vinyl bond content when the conjugated diene compound is butadiene.

Next, a method of manufacturing the copolymer according to the present invention will be described in detail. However, the manufacturing method described in detail below is merely an example. The copolymer of the present invention can be manufactured by controlling the introduction of monomers to a polymerization system for copolymerizing a conjugated diene compound and a non-conjugated olefin. Specifically, the method of manufacturing the copolymer according to the present invention has a feature in that the introduction of a conjugated diene compound is controlled in the presence of a non-conjugated olefin so as to control the chain structure of the copolymer, to thereby control the arrangement of monomer units in the copolymer. According to the present invention, the term “polymerization system” herein refers to a location where a conjugated diene compound and a non-conjugated olefin are copolymerized, and a specific example thereof includes a reaction container or the like.

Here, the introduction of a conjugated diene compound may either be continuous introduction or divisional introduction. Further, the continuous introduction and the divisional introduction may be employed in combination. The continuous introduction herein refers to, for example, adding a conjugated diene compound at a certain addition rate for a certain period.

Introducing a conjugated diene compound into a polymerization system for copolymerizing the conjugated diene compound and a non-conjugated olefin allows control of the concentration ratio of monomers in the polymerization system, with the result that the chain structure (that is, the arrangement of monomer units) in the copolymer to be obtained can be defined. Further, a conjugated diene compound is introduced in the presence of a non-conjugated olefin in the polymerization system, to thereby suppress generation of homopolymer of a conjugated diene compound. The polymerization of a non-conjugated olefin may be started prior to the introduction of a conjugated diene compound.

Specifically, as the aforementioned method of manufacturing a tapered copolymer, the following methods can be exemplified: (1) a method comprising: introducing a conjugated diene compound to a polymerization system in which the polymerization of a non-conjugated olefin is started in advance, in the presence of a non-conjugated olefin; and newly introducing a conjugated diene compound atleast once and/or continuously into the polymerization system which includes a copolymer resulting from the polymerization of a non-conjugated olefin and a conjugated diene compound; (2) a method comprising: introducing a conjugated diene compound at least once or continuously in the presence of a non-conjugated olefin; and then continuously introducing a conjugated diene compound into the polymerization system including a copolymer resulting from the polymerization of a non-conjugated olefin and a conjugated diene compound. Further, these methods can both be employed in combination for polymerization to synthesize a tapered copolymer.

The aforementioned manufacturing method is not specifically limited as long as the introduction of monomers into a polymerization system is specified as described above, and may employ any polymerization method including, for example, solution polymerization, suspension polymerization, liquid phase bulk polymerization, emulsion polymerization, vapor phase polymerization, and solid state polymerization.

In the aforementioned manufacturing method, the introduction of a conjugated diene compound needs to be controlled. Specifically, it is preferred to control the amount of a conjugated diene compound to be introduced and the number of times to introduce the conjugated diene compound. Examples of a method of controlling the introduction of a conjugated diene compound may include, but not limited to: a controlling method based on a computer program or the like; and an analog control method with the use of a timer or the like. Further, as described above, the method of introducing a conjugated diene compound is not specifically limited, and may be exemplified by continuous introduction or divisional introduction. Here, in divisionally introducing a conjugated diene compound, the number of times to introduce the conjugated diene is not specifically limited.

Further, the aforementioned manufacturing method requires the presence of a non-conjugated olefin upon introduction of a conjugated diene compound, and thus it is preferred to continuously feed a non-conjugated olefin to the polymerization system. Here, how to feed the non-conjugated olefin is not specifically limited.

According to the method of manufacturing the copolymer of the present invention, it is preferred to polymerize a conjugated diene compound and a non-conjugated olefin in the presence of the following polymerization catalyst or polymerization catalyst composition, in view of efficiently enhancing the polymerization. In the case of using a solvent for polymerization, any solvent that is inactive in polymerization can be used, including, for example, toluene, hexane, cyclohexane, and a mixture thereof.

<First Polymerization Catalyst Composition>

An example of the aforementioned polymerization catalyst composition preferably includes a polymerization catalyst composition (hereinafter, also referred to as first polymerization catalyst composition) including at least one complex selected from a group consisting of: a metallocene complex represented by the following general formula (I); a metallocene complex represented by the following general formula (II); and a half metallocene cation complex represented by the following general formula (III):

(In the formula (I), M represents a lanthanoid element, scandium, or yttrium; Cp^(R) each independently represents an unsubstituted or substituted indenyl group; R^(a) to R^(f) each independently represent a hydrogen atom or an alkyl group having 1 to 3 carbon atoms; L represents a neutral Lewis base; and w represents an integer of 0 to 3.);

(In the formula (II), M represents a lanthanoid element, scandium, or yttrium; Cp^(R) each independently represents an unsubstituted or substituted indenyl group; X′ represents a hydrogen atom, a halogen atom, an alkoxy group, a thiolate group, an amide group, a silyl group, or a hydrocarbon group having 1 to 20 carbon atoms; L represents a neutral Lewis base; and w represents an integer of 0 to 3.); and

(In the formula (III), M represents a lanthanoid element, scandium, or yttrium; Cp^(R′) each independently represents an unsubstituted or substituted cyclopentadienyl, indenyl, fluorenyl group; X represents a hydrogen atom, a halogen atom, an alkoxy group, a thiolate group, an amide group, a silyl group, or a hydrocarbon group having 1 to 20 carbon atoms; L represents a neutral Lewis base; w represents an integer of 0 to 3; and [B]⁻ represents a non-coordinating anion.) The first polymerization catalyst composition may further include another component such as a co-catalyst, which is contained in a general polymerization catalyst composition containing a metallocene complex. Here, the metallocene complex is a complex compound having one or more cyclopentadienyl groups or derivative of cyclopentadienyl groups bonded to the central metal. In particular, a metallocene complex may be referred to as half metallocene complex when the number of cyclopentadienyl group or derivative thereof bonded to the central metal is one.

In the polymerization system, the concentration of the complex contained in the first polymerization catalyst composition is preferably defined to fall within a range of 0.1 mol/L to 0.0001 mol/L.

In the metallocene complex represented by the general formulae (I) and (II) above, Cp^(R) in the formulae represents an unsubstituted or substituted indenyl group. Cp^(R) having an indenyl ring as a basic skeleton may be represented by C₉H_(7-X)R_(X) or C₉H_(11-X)R_(X). Here, X represents an integer of 0 to 7 or 0 to 11. R each independently preferably represents a hydrocarbyl group or a metalloid group. The hydrocarbyl group preferably has 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms, and still more preferably 1 to 8 carbon atoms. Preferred specific examples of the hydrocarbyl group include a methyl group, an ethyl group, a phenyl group, and a benzyl group. On the other hand, examples of metalloid in the metalloid group include germyl (Ge), stannyl (Sn), and silyl (Si). In addition, the metalloid group preferably has a hydrocarbyl group which is similar to the hydrocarbyl group described above. Specific examples of the metalloid group include a trimethylsilyl group. Specific examples of the substituted indenyl group include 2-phenyl indenyl, 2-methyl indenyl, and 1-methyl-2-phenyl indenyl group. Two Cp^(R) in the general formulae (I) and (II) may be the same as or different from each other.

In the half metallocene cation complex represented by the general formula (III), Cp^(R′) in the formula represents a substituted or unsubstituted cyclopentadienyl, indenyl, or fluorenyl group, with the substituted or unsubstituted indenyl group being preferred. Cp^(R′) having a cyclopentadienyl ring as a basic skeleton is represented by C₅H_(5-X)R_(X). Here, X represents an integer of 0 to 5. Further, R each independently preferably represents a hydrocarbyl group or a metalloid group. The hydrocarbyl group preferably has 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms, and still more preferably 1 to 8 carbon atoms. Preferred specific examples of the hydrocarbyl group include a methyl group, an ethyl group, a propyl group, a phenyl group, and a benzyl group. Examples of metalloid in the metalloid group include germyl (Ge), stannyl (Sn), and silyl (Si). In addition, the metalloid group preferably has a hydrocarbyl group which is similar to the hydrocarbyl group described above. Specific examples of the metalloid group include a trimethylsilyl group. Cp^(R′) having a cyclopentadienyl ring as a basic skeleton is specifically exemplified as follows.

(In the formula, R represents a hydrogen atom, a methyl group, or an ethyl group.)

In the general formula (III), Cp^(R′) having an indenyl ring as a basic skeleton is defined as the same as Cp^(R) in the general formula (I), and preferred examples thereof are also the same as those of Cp^(R) in the general formula (I).

In the general formula (III), Cp^(R′) having the fluorenyl ring above as a basic skeleton may be represented by C₁₃H_(9-X)R_(X) or C₁₃H_(17-X)R_(X). Here, X represents an integer of 0 to 9 or 0 to 17. R independently preferably represents a hydrocarbyl group or a metalloid group. The hydrocarbyl group preferably has 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms, and still more preferably 1 to 8 carbon atoms. Preferred specific examples of the hydrocarbyl group include a methyl group, an ethyl group, a phenyl group, and a benzyl group. On the other hand, examples of metalloid in the metalloid group include germyl (Ge), stannyl (Sn), and silyl (Si). In addition, the metalloid group preferably has a hydrocarbyl group which is similar to the hydrocarbyl group described above. A specific example of the metalloid group includes a trimethylsilyl group.

The central metal represented by M in the general formulae (I), (II), and (III) represents a lanthanoid element, scandium, or yttrium. The lanthanoid elements include 15 elements with atomic numbers 57 to 71, and may be any one of them. Preferred examples of the central metal represented by M include samarium (Sm), neodymium (Nd), praseodymium (Pr), gadolinium (Gd), cerium (Ce), holmium (Ho), scandium (Sc), and yttrium (Y).

The metallocene complex represented by the general formula (I) includes a silyl amide ligand represented by [—N(SiR₃)₂]. Groups represented by R(R^(a) to R^(f) in the general formula (I)) in the silyl amide ligand each independently represent a hydrogen atom or an alkyl group having 1 to 3 carbon atoms, and it is preferred that at least one of R^(a) to R^(f) represents a hydrogen atom. With at least one of R^(a) to R^(f) representing a hydrogen atom, the catalyst can be synthesized with ease, and the height around silicon can be reduced, to thereby allow the non-conjugated olefin to be easily introduced.

Based on the same objective, it is further preferred that at least one of R^(a) to R^(c) represents a hydrogen atom, and at least one of R^(d) to R^(f) represents a hydrogen atom. A methyl group is preferred as the alkyl group.

The metallocene complex represented by the general formula (II) includes a silyl ligand represented by [—SiX′₃]. X′ in the silyl ligand represented by [—SiX′₃] is a group defined as the same as X in the general formula (III) described below, and preferred examples thereof are also the same as those of X in the general formula (III).

In the general formula (III), X represents a group selected from a group consisting of a hydrogen atom, a halogen atom, an alkoxy group, a thiolate group, an amide group, a silyl group, and a hydrocarbon group having 1 to 20 carbon atoms. In the general formula (III), the alkoxy group represented by X may be any one of aliphatic alkoxy groups such as a methoxy group, an ethoxy group, a propoxy group, an n-butoxy group, an isobutoxy group, a sec-butoxy group, and a tert-butoxy group; and aryl oxide groups (aromatic alkoxy groups) such as a phenoxy group, a 2,6-di-tert-butylphenoxy group, a 2,6-diisopropylphenoxy group, a 2,6-dineopentylphenoxy group, a 2-tert-butyl-6-isopropylphenoxy group, a 2-tert-butyl-6-neopentylphenoxy group, and a 2-isopropyl-6-neopentylphenoxy group, with the 2,6-di-tert-butylphenoxy group being preferred.

In the general formula (III), the thiolate group represented by X may be any one of: aliphatic thiolate groups such as a thiomethoxy group, a thioethoxy group, a thiopropoxy group, a thio-n-butoxy group, a thioisobutoxy group, a thio-sec-butoxy group, and a thio-tert-butoxy group; and aryl thiolate groups such as a thiophenoxy group, a 2,6-di-tert-butylthiophenoxy group, a 2,6-diisopropylthiophenoxy group, a 2,6-dineopentylthiophenoxy group, a 2-tert-butyl-6-isopropylthiophenoxy group, a 2-tert-butyl-6-thioneopentylphenoxy group, a 2-isopropyl-6-thioneopentylphenoxy group, and a 2,4,6-triisopropylthiophenoxy group, with the 2,4,6-triisopropylthiophenoxy group being preferred.

In the general formula (III), the amide group represented by X may be any one of: aliphatic amide groups such as a dimethyl amide group, a diethyl amide group, and a diisopropyl amide group; arylamide groups such as a phenyl amide group, a 2,6-di-tert-butylphenyl amide group, a 2,6-diisopropylphenyl amide group, a 2,6-dineopentylphenyl amide group, a 2-tert-butyl-6-isopropylphenyl amide group, a 2-tert-butyl-6-neopentylphenyl amide group, a 2-isopropyl-6-neopentylphenyl amide group, and a 2,4,6-tri-tert-butylphenyl amide group; and bistrialkylsilyl amide groups such as a bistrimethylsilyl amide group, with the bistrimethylsilyl amide group being preferred.

In the general formula (III), the silyl group represented by X may be any one of a trimethylsilyl group, a tris(trimethylsilyl)silyl group, a bis(trimethylsilyl)methylsilyl group, a trimethylsilyl(dimethyl)silyl group, and a triisopropylsilyl(bistrimethylsilyl)silyl group, with the tris(trimethylsilyl)silyl group being preferred.

In the general formula (III), the halogen atom represented by X may be any one of a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom, with the chlorine atom and the iodine atom being preferred. Specific examples of the hydrocarbon group having 1 to 20 carbon atoms include: linear or branched aliphatic hydrocarbon groups such as a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a sec-butyl group, a tert-butyl group, a neopentyl group, a hexyl group, and an octyl group; aromatic hydrocarbon groups such as a phenyl group, a tolyl group, and a naphthyl group; aralkyl groups such as a benzyl group; and hydrocarbon groups such as a trimethylsilylmethyl group and a bistrimethylsilylmethyl group each containing a silicon atom, with the methyl group, the ethyl group, the isobutyl group, the trimethylsilylmethyl group, and the like being preferred.

In the general formula (III), the bistrimethylsilyl amide group and the hydrocarbon group having 1 to 20 carbon atoms are preferred as X.

In the general formula (III), examples of the non-coordinating anion represented by [B]⁻ include tetravalent boron anions. Examples of the tetravalent boron anion include tetraphenyl borate, tetrakis(monofluorophenyl)borate, tetrakis(difluorophenyl)borate, tetrakis(trifluorophenyl)borate, tetrakis(tetrafluorophenyl)borate, tetrakis(pentafluorophenyl)borate, tetrakis(tetrafluoromethylphenyl)borate, tetra(tolyl)borate, tetra(xylyl)borate, (tripheyl, pentafluorophenyl)borate, [tris(pentafluorophenyl), phenyl]borate, and tridecahydride-7,8-dicarbaundecaborate, with the tetrakis(pentafluorophenyl)borate being preferred.

The metallocene complexes represented by the general formulae (I) and (II) and the half metallocene cation complex represented by the general formula (III) may include 0 to 3, preferably 0 or 1 neutral Lewis bases represented by L. Examples of the neutral Lewis base L include tetrahydrofuran, diethyl ether, dimethylaniline, trimethylphosphine, lithium chloride, neutral olefins, and neutral diolefins. When a plurality of neutral Lewis bases represented by L are incorporated, respective L may be the same as or different from each other.

The metallocene complexes represented by the general formulae (I) to (II), and the half metallocene cation complex represented by the general formula (III) may be each present as a monomer or as a dimer or a multimer having more monomers.

The metallocene complex represented by the general formula (I) can be obtained by, for example, subjecting a lanthanoid trishalide, a scandium trishalide, or a yttrium trishalide to reaction in a solvent with a salt of indenyl (for example, a potassium salt or a lithium salt) and a salt of bis(trialkylsilyl)amide (for example, a potassium salt or a lithium salt). The reaction temperature only needs to be set to about room temperature, and thus the complex can be manufactured in mild conditions. In addition, reaction time is arbitrary, but about several hours to several tens of hours. A reaction solvent is not particularly limited, with a solvent that solves a raw material and a product being preferred, and for example, toluene may be used. In the following, a reaction example for obtaining the complex represented by the general formula (I) is described.

(In the Formula, X″ represents a halide.)

The metallocene complex represented by the general formula (II) can be obtained by, for example, subjecting a lanthanoid trishalide, a scandium trishalide, or a yttrium trishalide to reaction in a solvent with a salt of indenyl (for example, a potassium salt or a lithium salt) and a salt of silyl (for example, a potassium salt or a lithium salt). The reaction temperature only needs to be set to about room temperature, and thus the complex can be manufactured in mild conditions. In addition, reaction time is arbitrary, but about several hours to several tens of hours. A reaction solvent is not particularly limited, with a solvent that solves a raw material and a product being preferred, and for example, toluene may be used. In the following, a reaction example for obtaining the complex represented by the general formula (II) is described.

(In the Formula, X″ represents a halide.)

The half metallocene cation complex represented by the general formula (III) can be obtained by, for example, the following reaction:

In the general formula (IV) representing a compound: M represents a lanthanoid element, scandium, or yttrium; Cp^(R′) independently represents an unsubstituted or substituted cyclopentadienyl, indenyl, or fluorenyl; X represents a hydrogen atom, a halogen atom, an alkoxy group, a thiolate group, an amide group, a silyl group, or a hydrocarbon group having 1 to 20 carbon atoms; L represents a neutral Lewis base; and w represents an integer of 0 to 3. Further, in the general formula [A]⁺[B]⁻ representing an ionic compound, [A]⁺ represents a cation; and [B]⁻ represents a non-coordinating anion.

Examples of the cation represented by [A]⁺ include a carbonium cation, an oxonium cation, an amine cation, a phosphonium cation, a cycloheptatrienyl cation, and a ferrocenium cation containing a transition metal. Examples of the carbonium cation include trisubstituted carbonium cations such as a triphenylcarbonium cation and a tri(substituted phenyl)carbonium cation. Specific examples of the tri(substituted phenyl)carbonium cation include a tri(methylphenyl)carbonium cation. Examples of the amine cation include: trialkylammonium cations such as a trimethylammonium cation, a triethylammonium cation, a tripropylammonium cation, and a tributylammonium cation; N,N-dialkylanilinium cations such as a N,N-dimethylanilinium cation, a N,N-diethylanilinium cation, and a N,N-2,4,6-pentamethylanilinium cation; and dialkylammonium cations such as a diisopropylammonium cation and a dicyclohexylammonium cation. Examples of the phosphonium cation include triarylphosphonium cations such as a triphenylphosphonium cation, a tri(methylphenyl)phosphonium cation, and a tri(dimethylphenyl)phosphonium cation. Of those cations, the N,N-dialkylanilinium cations or the carbonium cations are preferred, and the N,N-dialkylanilinium cations are particularly preferred.

In the general formula [A]⁺[B]⁻ representing the ionic compound to be used in the above reaction is a compound obtained by combining any one selected from the non-coordinating anions described above and any one selected from the cations described above. Preferred examples thereof include N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate and triphenylcarbonium tetrakis(pentafluorophenyl)borate. The ionic compound represented by the general formula [A]⁺[B]⁻ is added in an amount of preferably 0.1-fold mol to 10-fold mol and more preferably about 1-fold mol, with respect to the metallocene complex. When the half metallocene cation complex represented by the general formula (III) is used in polymerization reaction, the half metallocene cation complex represented by the general formula (III) may be directly supplied to the polymerization system, or alternatively, the compound represented by the general formula (IV) and the ionic compound represented by the general formula [A]⁺[B]⁻ may be separately supplied to the polymerization system, to thereby form the half metallocene cation complex represented by the general formula (III) in the reaction system. In addition, the half metallocene cation complex represented by the general formula (III) may be formed in the reaction system by using the metallocene complex represented by the general formula (I) or (II) and the ionic compound represented by the general formula [A]⁺[B]⁻ in combination.

Structures of the metallocene complex represented by the general formula (I) or (II) and of the half metallocene cation complex represented by the general formula (III) is preferably determined by X-ray crystallography.

The co-catalyst that can be contained in the first polymerization catalyst composition may be arbitrarily selected from components used as the co-catalyst for the general polymerization catalyst composition containing a metallocene complex. Preferred examples of the co-catalyst include aluminoxanes, organic aluminum compounds, and the above ionic compounds. These co-catalysts may be contained alone or in combination of two or more.

The aluminoxane is preferably an alkyl aluminoxane. Examples of the alkyl aluminoxane include methyl aluminoxane (MAO) and modified methyl aluminoxanes. In addition, preferred examples of the modified methyl aluminoxane include MMAO-3A (manufactured by Tosoh Finechem Corporation). A content of the aluminoxane in the first polymerization catalyst composition is preferably about 10 to 1,000, more preferably about 100, at an element ratio (Al/M) of the aluminum element Al of the aluminoxane to the central metal element M in the metallocene complex.

On the other hand, a preferred example of the organic aluminum compounds may include an organic aluminum compound represented by a general formula AlRR′R″ (where R and R′ each independently represent a hydrocarbon group of C₁ to C₁₀ or a hydrogen atom, and R″ is a hydrocarbon group of C₁ to C₁₀). Specific examples of the organic aluminum compound include a trialkyl aluminum, a dialkyl aluminum chloride, an alkyl aluminum dichloride, and a dialkyl aluminum hydride, with the trialkyl aluminum being preferred. Further, examples of the trialkyl aluminum include triethyl aluminum and triisobutyl aluminum. A content of the organic aluminum compound in the first polymerization catalyst composition is preferably 1-fold mol to 50-fold mol and more preferably about 10-fold mol, with respect to the metallocene complex.

In the first polymerization catalyst composition, the metallocene complex represented by the general formulae (I) and (II) and the half metallocene complex represented by the general formula (III) may be combined with an appropriate co-catalyst, to thereby increase the cis-1,4 bond content and the molecular weight of a copolymer to be obtained.

<Second Polymerization Catalyst Composition>

Another preferred example of the aforementioned polymerization catalyst composition may include:

a polymerization catalyst composition (hereinafter, also referred to as second polymerization catalyst composition) containing:

component (A): a rare earth element compound or a reactant of a rare earth element compound and a Lewis base, with no bond formed between the rare earth element and carbon;

component (B): at least one selected from a group consisting of: an ionic compound (B-1) composed of a non-coordinating anion and a cation; an aluminoxane (B-2); and at least one kind of halogen compound (B-3) from among a Lewis acid, a complex compound of a metal halide and a Lewis base, and an organic compound containing active halogen. Further, if the polymerization catalyst composition contains at least one kind of the ionic compound (B-1) and the halogen compound (B-3), the polymerization catalyst composition further contains:

component (C): an organic metal compound represented by the following general formula (I):

YR¹ _(a)R² _(b)R³ _(c)  (i)

(where Y is a metal selected from Group 1, Group 2, Group 12, and Group 13 of the periodic table; R¹ and R² are the same or different hydrocarbon groups each having 1 to 10 carbon atoms or a hydrogen atom; and R³ is a hydrocarbon group having 1 to 10 carbon atoms, in which R³ may be the same as or different from R¹ or R² above, with a being 1 and b and c both being 0 when Y is a metal selected from Group 1 of the periodic table, a and b being 1 and c being 0 when Y is a metal selected from Group 2 and Group 12 of the periodic table, a, b, and c are all 1 when Y is a metal selected from Group 13 of the periodic table). The ionic compound (B-1) and the halogen compound (B-3) do not have carbon atoms to be fed to the component (A), and thus the component (C) becomes necessary as a source of feeding carbon to the component (A). Here, the polymerization catalyst composition still may include the component (C) even if the polymerization catalyst composition includes the aluminoxane (B-2). Further, the second polymerization catalyst composition may further include another component such as a co-catalyst, which is contained in a general rare earth element compound-based polymerization catalyst composition. In the polymerization system, the concentration of the component (A) contained in the second polymerization catalyst composition is preferably defined to fall within a range of 0.1 mol/L to 0.0001 mol/L.

The component (A) contained in the second polymerization catalyst composition is a rare earth element compound or a reactant of the rare earth element compound and a Lewis base. Here, a rare earth element compound or a reactant of the rare earth element compound and a Lewis base do not have a direct bond formed between the rare earth element and carbon. When the rare earth element compound or a reactant thereof does not have a direct bond formed between a rare earth element and carbon, the resulting compound is stable and easy to handle. Here, the rare earth element compound refers to a compound containing a lanthanoid element, scandium, or yttrium. The lanthanoid elements include elements with atomic numbers 57 to 71 of the periodic table. Specific examples of the lanthanoid element include lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbio, tulio, itterbio, and lutezio. These components (A) may be contained alone or in combination of two or more.

The rare earth element compound is preferably composed of a rare earth metal of a bivalent or trivalent salt or of a complex compound, and further preferably a rare earth element compound containing at least one ligand selected from a hydrogen atom, a halogen atom, and an organic compound residue. Further, the rare earth element compound or the reactant of the rare earth element compound and the Lewis base is represented by the following general formula (XI) or (XII):

M¹¹X¹¹ ₂·L¹¹ _(w)  (XI)

M¹¹X¹¹ ₃·L¹¹ _(w)  (XII)

(where: M¹¹ represents a lanthanoid element, scandium, or yttrium; X¹¹ each independently represent a hydrogen atom, a halogen atom, an alkoxy group, a thiolate group, an amide group, a silyl group, an aldehyde residue, a ketone residue, a carboxylic acid residue, a thicarboxylic acid residue, or a phosphorous compound residue; L¹¹ represents a Lewis base; and w represents 0 to 3).

Specific examples of a group (ligand) to form a bond to the rare earth element of the rare earth element compound include: a hydrogen atom; aliphatic alkoxy groups such as a methoxy group, an ethoxy group, a propoxy group, an n-butoxy group, an isobutoxy group, a sec-butoxy group, and a tert-butoxy group; aromatic alkoxy groups such as a phenoxy group, a 2,6-di-tert-butylphenoxy group, a 2,6-diisopropylphenoxy group, a 2,6-dineopentylphenoxy group, a 2-tert-butyl-6-isopropylphenoxy group, a 2-tert-butyl-6-neopentylphenoxy group, and a 2-isopropyl-6-neopentylphenoxy group; aliphatic thiolate groups such as thiomethoxy group, a thioethoxy group, a thiopropoxy group, a thio-n-butoxy group, a thioisobutoxy group, a thio-sec-butoxy group, and a thio-tert-butoxy group; aryl thiolate groups such as a thiophenoxy group, a 2,6-di-tert-butylthiophenoxy group, a 2,6-diisopropylthiophenoxy group, a 2,6-dineopentylthiophenoxy group, a 2-tert-butyl-6-isopropylthiophenoxy group, a 2-tert-butyl-6-thioneopentylphenoxy group, a 2-isopropyl-6-thioneopentylphenoxy group, and a 2,4,6-triisopropylthiophenoxy group; aliphatic amide groups such as a dimethyl amide group, a diethyl amide group, a diisopropyl amide group; arylamide groups such as a phenyl amide group, a 2,6-di-tert-butylphenyl amide group, a 2,6-diisopropylphenyl amide group, a 2,6-dineopentylphenyl amide group, a 2-tert-butyl-6-isopropylphenyl amide group, a 2-tert-butyl-6-neopentylphenyl amide group, a 2-isopropyl-6-neopentylphenyl amide group, and a 2,4,6-tert-butylphenyl amide group; bistrialkylsilyl amide groups such as a bistrimethylsilyl amide group; silyl groups such as a trimethylsilyl group, a tris(trimethylsilyl)silyl group, a bis(trimethylsilyl)methylsilyl group, a trimethylsilyl(dimethyl)silyl group, and a triisopropylsilyl(bistrimethylsilyl)silyl group; halogen atoms such as a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom. Other examples may include: residues of aldehyde such as salicylaldehyde, 2-hydroxy-1-naphthaldehyde, and 2-hydroxy-3-naphthaldehyde; residues of hydroxyphenone such as 2′-hydroxyacetophenone, 2′-hydroxybutyrophenone, and 2′-hydroxypropiophenone; residues of diketone such as acetylacetone, benzoylacetone, propionylaceton, isobutyl acetone, valerylacetone, and ethylacetylacetone; residues of an carboxylic acid such as an isovaleric acid, a caprylic acid, an octanoic acid, a lauric acid, a myristic acid, a palmitic acid, a stearic acid, an isostearic acid, an oleic acid, a linoleic acid, a cyclopentanecarboxylic acid, a naphthenic acid, an ethylhexanoic acid, a pivalic acid, a versatic acid (trade name of a product manufactured by Shell Chemicals Japan Ltd., a synthetic acid composed of a mixture of C10 monocarboxylic acid isomers), a phenylacetic acid, a benzoic acid, 2-naphthoate acid, a maleic acid, and a succinic acid; residues of thicarboxylic acid such as a hexanethioic acid, 2,2-dimethylbutanethioic acid, a decanethioic acid, and a thiobenzoic acid; residues of phosphoric acid ester such as a phosphoric acid dibutyl, a phosphoric acid dipentyl, a phosphoric acid dihexyl, a phosphoric acid diheptyl, a phosphoric acid dioctyl, phosphoric acid bis(2-ethylhexyl), a phosphoric acid bis(1-methylheptyl), a phosphoric acid dilauryl, a phosphoric acid dioleyl, a phosphoric acid diphenyl, a phosphoric acid bis(p-nonylphenyl), a phosphoric acid bis(polyethylene glycol-p-nonylphenyl), a phosphoric acid(butyl)(2-ethylhexyl), a phosphoric acid(1-methylheptyl)(2-ethylhexyl), and a phosphoric acid(2-ethylhexyl)(p-nonylphenyl); residues of phosphonic acid ester such as a 2-ethylhexyl phosphonic acid monobutyl, a 2-ethylhexyl phosphonic acid mono-2-ethylhexyl, a phenylphosphonic acid mono-2-ethylhexyl, a 2-ethylhexyl phosphonic acid mono-p-nonylphenyl, a phosphonic acid mono-2-ethylhexyl, a phosphonic acid mono-1-methylheptyl, a and phosphonic acid mono-p-nonylphenyl; residues of phosphinic acid such as a dibutylphosphinic acid, a bis(2-ethylhexyl)phosphinic acid, a bis(1-methylheptyl)phosphinic acid, a dilauryl phosphinic acid, a dioleyl phosphinic acid, a diphenyl phosphinic acid, a bis(p-nonylphenyl)phosphinic acid, a butyl(2-ethylhexyl) phosphinic acid, (2-ethylhexyl)(2-methylhexyl)(1-methylheptyl)phosphinic acid, an (2-ethylhexyl)(p-nonylphenyl) phosphinic acid, a butyl phosphinic acid, 2-ethylhexyl phosphinic acid, a 1-methylheptyl phosphinic acid, an oleyl phosphinic acid, a lauryl phosphinic acid, a phenyl phosphinic acid, and a p-nonylphenyl phosphinic acid. These ligands may be used alone or in combination of two or more. Of those, amide groups, which easily form active species through reaction with co-catalyst, are preferred.

As to the component (A) used in the second polymerization catalyst composition, examples of the Lewis base to react with the rare earth element compound may include: tetrahydrofuran; diethyl ether; dimethylaniline; trimethylphosphine; lithium chloride, neutral olefins, and neutral diolefins. Here, in the case where the rare earth element compound reacts with a plurality of Lewis bases (in the case where w is 2 or 3 in Formulae (XI) and (XII)), the Lewis base L¹¹ in each Formula may be the same as or different from each other.

The component (B) contained in the second polymerization catalyst composition is at least one compound selected from a group consisting of: an ionic compound (B-1); an aluminoxane (B-2); and a halogen compound (B-3). The total content of the component (B) contained in the second polymerization catalyst composition is preferably defined to fall within a range of 0.1-fold mol to 50-fold mol, with respect to the component (A).

The ionic compound represented by (B-1) is formed of non-coordinating anion and cation, and an example thereof includes: an ionic compound that reacts with the rare earth element compound as the component (A) or with the reactant resulting from Lewis base and the rare earth element compound, so as to form a cationic transition metal compound. Here, examples of the non-coordinating anion include: tetraphenyl borate, tetrakis(monofluorophenyl)borate, tetrakis(difluorophenyl)borate, tetrakis(trifluorophenyl)borate, tetrakis(tetrafluorophenyl)borate, tetrakis(pentafluorophenyl)borate, tetrakis(tetrafluoromethylphenyl)borate, tetra(tolyl)borate, tetra(xylyl)borate, (tripheyl, pentafluorophenyl)borate, [tris(pentafluorophenyl), phenyl]borate, and tridecahydride-7,8-dicarbaundecaborate.

Meanwhile, examples of the cation may include a carbonium cation, an oxonium cation, an ammonium cation, a phosphonium cation, a cycloheptatrienyl cation, and a ferrocenium cation containing a transition metal. Specific examples of the carbonium cation include trisubstituted carbonium cations such as a triphenylcarbonium cation and a tri(substituted phenyl)carbonium cation, and more specific examples of the tri(substituted phenyl)carbonium cation include a tri(methylphenyl)carbonium cation and a tri(dimethylphenyl)carbonium cation. Examples of the ammonium cation include: trialkylammonium cations such as a trimethylammonium cation, a triethylammonium cation, a tripropylammonium cation, and a tributylammonium cation (such as a tri(n-butyl)ammonium cation); N,N-dialkylanilinium cations such as a N,N-dimethylanilinium cation, N,N-diethylanilinium cation, and a N,N-2,4,6-pentamethylanilinium cation; and dialkylammonium cations such as a diisopropylammonium cation and a dicyclohexylammonium cation. Specific examples of the phosphonium cation include triarylphosphonium cations such as a triphenylphosphonium cation, a tri(methylphenyl)phosphonium cation, and a tri(dimethylphenyl)phosphonium cation. Therefore, the ionic compound may preferably be a compound obtained by combining any one selected from the non-coordinating anions described above and any one selected from the cations described above. Specific examples thereof preferably include a N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate and a triphenylcarbonium tetrakis(pentafluorophenyl)borate. These ionic compounds may be contained alone or in combination of two or more. The content of the ionic compound in the second polymerization catalyst composition is preferably 0.1-fold mol to 10-fold mol, and more preferably about 1-fold mol, with respect to the component (A).

The aluminoxane represented by (B-2) is a compound obtained by contacting an organic aluminum compound with a condensation agent, and examples thereof include: a chain type aluminoxane or a cyclic aluminoxane, both having a repeating unit represented by the general formula (—Al(R′)O—) (where R′ is a hydrocarbon group having 1 to 10 carbon atoms and may be partly substituted with halogen atom and/or alkoxy group, and the polymerization degree of the repeating unit is preferably at least 5, more preferably at least 10). Here, specific examples of R′ include a methyl group, an ethyl group, a propyl group, and isobutyl group, with the methyl group being preferred. Further, examples of the organic aluminum compound used as a raw material of the aluminoxane may include: trialkyl aluminums such as trimethyl aluminum, triethyl aluminum, triisobutyl aluminum and the like; and mixtures thereof, with the trimethyl aluminum being particularly preferred. For example, an aluminoxane obtained using, as a raw material, a mixture of trimethyl aluminum and tributyl aluminum can be suitably used. The content of aluminoxane in the second polymerization catalyst composition is preferably about 10 to 1,000 at an element ratio (Al/M) of the aluminum element Al of the aluminoxane to the rare earth element M forming the component (A).

The halogen compound represented by (B-3) includes at least one of: a Lewis acid; a complex compound of a metal halide and a Lewis base; and an organic compound containing active halogen, and is capable of reacting with, for example, the rare earth element compound as the component (A) or with the reactant resulting from Lewis base and the rare earth element compound, so as to form a cationic transition metal compound. The content of the halogen compound in the second polymerization catalyst composition is preferably 1-fold mol to 5-fold mol, with respect to the component (A).

Examples of the Lewis acid may include: a boron-containing halogen compound such as B(C₆F₅)₃ and an aluminum-containing halogen compound such as Al(C₆F₅)₃, and may also include a halogen compound containing an element of Group III, Group IV, Group V, Group VI, and Group VIII of the periodic table. Preferred examples thereof include an aluminum halide or an organometallic halide. Preferred examples of the halogen element include chlorine and bromine. Specific examples of the Lewis acid include: a methyl aluminum dibromide; a methyl aluminum dichloride; an ethyl aluminum dibromide; an ethyl aluminum dichloride; a butyl aluminum dibromide; a butyl aluminum dichloride; a dimethyl aluminum bromide; a dimethyl aluminum chloride; a diethyl aluminum bromide; a diethyl aluminum chloride; a dibutyl aluminum bromide; a dibutyl aluminum chloride; a methyl aluminum sesquibromide; a methyl aluminum sesquichloride; a ethyl aluminum sesquibromide; an ethyl aluminum sesquichloride; a dibutyltin dichloride; an aluminum tribromide; an antimony trichloride; an antimony pentachloride; a phosphorus trichloride; a phosphorus pentachloride; a tin tetrachloride; a titanium tetrachloride; and tungsten hexachloride, with the diethyl aluminum chloride, the ethyl aluminum sesquichloride, the ethyl aluminum dichloride, the diethyl aluminum bromide, the ethyl aluminum sesquibromide, and the ethyl aluminum dibromide being particularly preferred.

Preferred examples of the metal halide forming a complex compound of the metal halide and a Lewis base include: a beryllium chloride, a beryllium bromide; a beryllium iodide; a magnesium chloride; a magnesium bromide; a magnesium iodide; a calcium chloride; a calcium bromide; a calcium iodide; a barium chloride; a barium bromide; a barium iodide; a zinc chloride; a zinc bromide; a zinc iodide; a cadmium chloride; a cadmium chloride; a cadmium bromide; a cadmium iodide; a mercury chloride; a mercury bromide; a mercury iodide; a manganese chloride; a manganese bromide; a manganese iodide; a rhenium chloride; a rhenium bromide; a rhenium iodide; a copper chloride; a copper bromide; a copper iodide; a silver chloride; a silver bromide; a silver iodide; a gold chloride; a gold iodide; and a gold bromide, with the magnesium chloride, the calcium chloride, the barium chloride, the manganese chloride, the zinc chloride, and the copper chloride being preferred, and the magnesium chloride, the manganese chloride, the zinc chloride, and the copper chloride being particularly preferred.

Preferred examples of the Lewis base forming a complex compound of the metal halide and the Lewis base include: a phosphorus compound; a carbonyl compound; a nitrogen compound; an ether compound; and an alcohol. Specific examples thereof include: a tributyl phosphate; a tri-2-ethylhexyl phosphate; a triphenyl phosphate; a tricresyl phosphate; a triethylphosphine; a tributylphosphine; a triphenylphosphine; a diethylphosphinoethane; an acetylacetone; a benzoylacetone; a propionitrileacetone; a valerylacetone; an ethylacetylacetone; a methyl acetoacetate; an ethyl acetoacetate; a phenyl acetoacetate; a dimethyl malonate; a diphenyl malonate; an acetic acid; an octanoic acid; a 2-ethylhexoic acid; an oleic acid; a stearic acid; a benzoic acid; a naphthenic acid; a versatic acid; a triethylamine; a N,N-dimethylacetamide; a tetrahydrofuran; a diphenyl ether; a 2-ethylhexyl alcohol; an oleyl alcohol; stearyl alcohol; a phenol; a benzyl alcohol; a 1-decanol; and a lauryl alcohol, with the tri-2-ethylhexyl phosphate, the tricresyl phosphate; the acetylacetone, the 2-ethylhexoic acid, the versatic acid, the 2-ethylhexyl alcohol; the 1-decanol; and the lauryl alcohol being preferred.

The Lewis base is subjected to reaction with the metal halide in the proportion of 0.01 mol to 30 mol, preferably 0.5 mol to 10 mol, per 1 mol of the metal halide. The use of the reactant obtained from the reaction of the Lewis base can reduce residual metal in the polymer.

An example of the organic compound containing active halogen includes benzyl chloride.

The component (C) contained in the second polymerization catalyst composition is an organic compound represented by the general formula (I):

YR¹ _(a)R² _(b)R³ _(c)  (i)

(where Y is a metal selected from Group 1, Group 2, Group 12, and Group 13 of the periodic table; R¹ and R² are the same or different hydrocarbon groups each having 1 to 10 carbon atoms or a hydrogen atom; and R³ is a hydrocarbon group having 1 to 10 carbon atoms, in which R³ may be the same as or different from R¹ or R² above, a being 1 and b and c both being 0 when Y is a metal selected from Group 1 of the periodic table, a and b being 1 and c being 0 when Y is a metal selected from Group 2 and Group 12 of the periodic table, a, b, and c are all 1 when Y is a metal selected from Group 13 of the periodic table), and is preferably an organic aluminum compound represented by the general formula (X):

AlR¹¹R¹²R¹³  (X)

(where R¹¹ and R¹² are the same or different hydrocarbon groups each having 1 to 10 carbon atoms or a hydrogen atom; and R¹³ is a hydrocarbon group having 1 to 10 carbon atoms, in which R¹³ may be the same as or different from R¹¹ or R¹² above). Examples of the organic aluminum compound in the formula (X) include: a trimethyl aluminum, a triethyl aluminum, a tri-n-propyl aluminum, a triisopropyl aluminum, a tri-n-butyl aluminum, a triisobutyl aluminum, a tri-t-butyl aluminum, a tripentyl aluminum, a trihexyl aluminum, a tricyclohexyl aluminum, a trioctyl aluminum; a diethylaluminum hydride, a di-n-propyl aluminum hydride, a di-n-butyl aluminum hydride, a diisobutyl aluminum hydride, a dihexyl aluminum hydride; a diisohexyl aluminum hydride, a dioctyl aluminum hydride, a diisooctyl aluminum hydride; an ethyl aluminum dihydride, a n-propyl aluminum dihydride, and an isobutyl aluminum dihydride, with the triethyl aluminum, the triisobutyl aluminum, the diethyl aluminum hydride, and the diisobutyl aluminum hydride being preferred. The organic metal compounds as the component (C) may be contained alone or in combination of two or more. The content of the organic aluminum compound in the second polymerization catalyst composition is preferably 1-fold mol to 50-fold mol, and more preferably about 10-fold mol, with respect to the component (A).

<Polymerization Catalyst>

Examples of the polymerization catalyst suitably include: a metallocene-based composite catalyst represented by the following formula (A):

R_(a)MX_(b)QY_(b)  (A)

(where R each independently represents an unsubstituted or substituted indenyl group, the R being coordinated with M; M represents a lanthanoid element, scandium, or yttrium; X each independently represents a hydrocarbon group having 1 to 20 carbon atoms, the X being pt-coordinated with M and Q; Q represents a Group 13 element in the periodic table; Y each independently represents a hydrocarbon group having 1 to 20 carbon atoms or a hydrogen atom, the Y being coordinated with Q; and a and b each are 2), and more preferably include a metallocene-based composite catalyst represented by the following general formula (XX):

(where M²¹ represents a lanthanoid element, scandium, or yttrium; Cp^(R) each independently represents an unsubstituted or substituted indenyl group; R²¹ to R²² each independently represent a hydrocarbon group having 1 to 20 carbon atoms, the R²¹ and R²² being pt-coordinated with M²¹ and Al; and R²³ and R²⁴ each independently represent a hydrocarbon group having 1 to 20 carbon atoms or a hydrogen atom). Here, the metallocene-based composite catalyst is a compound having: a rare earth element such as lanthanoid element, scandium, or yttrium; and a Group 13 element in the periodic table. The use of these metallocene-based composite compounds such as an aluminum-based catalyst can reduce or eliminate the amount of alkyl aluminum to be used in the step of synthesizing a copolymer. Meanwhile, the use of a conventional catalyst system requires a large amount of alkyl aluminum to be used in synthesizing a copolymer. For example, a conventional catalyst system requires alkyl aluminum of at least 10 equivalents relative to a metal catalyst, whereas the metallocene-based composite catalyst of the present invention can exhibit an excellent catalytic effect through the addition of alkyl aluminum of only about 5 equivalents. The μ-coordination refers to a state of coordination which forms a crosslinked structure.

In the metallocene-based composite catalyst, the metal represented by M in the formula (A) is a lanthanoid element, scandium, or yttrium. The lanthanoid elements include 15 elements with atomic numbers 57 to 71, and may be any one of them. Preferred examples of the metal represented by M include samarium (Sm), neodymium (Nd), praseodymium (Pr), gadolinium (Gd), cerium (Ce), holmium (Ho), scandium (Sc), and yttrium (Y).

In the formula (A), R each independently represents an unsubstituted or substituted indenyl, the R being coordinated with the metal M. Specific examples of the substituted indenyl group include a 1,2,3-trimethyl indenyl group, a heptamethyl indenyl group, and a 1,2,4,5,6,7-hexamethyl indenyl group.

In the formula (A), Q represents a Group 13 element in the periodic table. Specific examples thereof include: boron, aluminum, gallium, indium, and thallium.

In the formula (A), X each independently represents a hydrocarbon group having 1 to 20 carbon atoms, the X being μ-coordinated with M and Q. Here, examples of the hydrocarbon group having 1 to 20 carbon atoms include: a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group, a decyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group, and a stearyl group.

In the formula (A), Y each independently represents a hydrocarbon group having 1 to 20 carbon atoms or a hydrogen atom, the Y being coordinated with Q. Here, examples of the hydrocarbon group having 1 to 20 carbon atoms include, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group, a decyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group, and a stearyl group.

On the other hand, in the metallocene-based composite catalyst represented by the formula (XX), the metal represented by M²¹ in the formula (XX) is a lanthanoid element, scandium, or yttrium. The lanthanoid elements include 15 elements with atomic numbers 57 to 71, and may be any one of them. Preferred examples of the metal represented by M¹ include samarium (Sm), neodymium (Nd), praseodymium (Pr), gadolinium (Gd), cerium (Ce), holmium (Ho), scandium (Sc), and yttrium (Y).

In the formula (XX), Cp^(R) represents an unsubstituted or substituted indenyl. Cp^(R) having an indenyl ring as a basic skeleton may be represented by C₉H_(7-X)R_(X) or C₉H_(11-X)R_(X). Here, X represents an integer of 0 to 7 or 0 to 11. R each independently preferably represents a hydrocarbyl group or a metalloid group. The hydrocarbyl group preferably has 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms, and still more preferably 1 to 8 carbon atoms. Specific examples of the hydrocarbyl group suitably include a methyl group, an ethyl group, a phenyl group, and a benzyl group. Meanwhile, examples of metalloid in the metalloid group include germyl (Ge), stannyl (Sn), and silyl (Si). In addition, the metalloid group preferably has a hydrocarbyl group, which is similar to the hydrocarbyl group described above. A specific example of the metalloid group is a trimethylsilyl group. Specific examples of the substituted indenyl group include 2-phenyl indenyl and 2-methyl indenyl group. Two Cp^(R) in the formula (XX) may be the same as or different from each other.

In the formula (XX), R²¹ and R²² each independently represent a hydrocarbon group having 1 to 20 carbon atoms, the R²¹ and R²² being pt-coordinated with M²¹ and Al. Here, examples of the hydrocarbon group having 1 to 20 carbon atoms include: a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group, a decyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group, and a stearyl group.

In the formula (XX), R²³ and R²⁴ each independently represent a hydrocarbon group having 1 to 20 carbon atoms or a hydrogen atom. Here, examples of the hydrocarbon group having 1 to 20 carbon atoms include: a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group, a decyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group, and a stearyl group.

The metallocene-based composite catalyst can be obtained by, for example, reacting with an organic aluminum compound represented by AlR²⁵R²⁶R²⁷ in a solvent, the metallocene complex represented by the formula (I) described in the first polymerization catalyst composition. The reaction may be carried out at temperatures around room temperature, and thus the metallocene-based composite catalyst can be manufactured under mild conditions. The reaction time is arbitrary, and may be about several hours to several tens of hours. The reaction solvent is not particularly limited, and any solvent including, for example, toluene and hexane, which are capable of dissolving the raw material and the product can be preferably used. The structure of the metallocene-based composite catalyst may preferably be determined by ¹H-NMR.

Specific examples of the organic aluminum compound include: a trimethyl aluminum, a triethyl aluminum, a tri-n-propyl aluminum, a triisopropyl aluminum, a tri-n-butyl aluminum, a triisobutyl aluminum, a tri-t-butyl aluminum, a tripentyl aluminum, a trihexyl aluminum, a tricyclohexyl aluminum, a trioctyl aluminum; a diethylaluminum hydride, a di-n-propyl aluminum hydride, a di-n-butyl aluminum hydride, a diisobutyl aluminum hydride, a dihexyl aluminum hydride; a diisohexyl aluminum hydride, a dioctyl aluminum hydride, a diisooctyl aluminum hydride; an ethyl aluminum dihydride, a n-propyl aluminum dihydride, and an isobutyl aluminum dihydride, with the triethyl aluminum, the triisobutyl aluminum, the diethyl aluminum hydride, and the diisobutyl aluminum hydride being preferred. These organic aluminum compounds may be contained alone or in combination of two or more. The content of the organic aluminum compound to be used for generating the metallocene-based composite catalyst is preferably 2-fold mol to 50-fold mol, and more preferably about 3-fold mol to 10-fold mol, with respect to the metallocene complex.

<Third Polymerization Catalyst Composition>

Preferred examples of the polymerization catalyst composition may further include a copolymerization compound including the metallocene-based composite catalyst and boron anion (hereinafter, the polymerization catalyst composition is also referred to as third polymerization catalyst composition). The third polymerization catalyst composition may further include another component such as a co-catalyst, which is contained in a general polymerization catalyst composition containing a metallocene complex. Here, the third polymerization catalyst composition is also referred to two-component catalyst, which has the metallocene-based composite catalyst and boron anion. The third polymerization catalyst composition is capable of producing, similarly to the metallocene-based composite catalyst, a copolymer of a conjugated diene compound and a non-conjugated olefin. In addition, the third polymerization catalyst composition further contains boron anion, which allows the content of each monomer component in the copolymer to be arbitrarily controlled.

In the third polymerization catalyst composition, a specific example of the boron anion forming the two-component catalyst includes a tetravalent boron anion. Examples thereof may include: a tetraphenyl borate, a tetrakis(monofluorophenyl)borate, a tetrakis(difluorophenyl)borate, a tetrakis(trifluorophenyl)borate, a tetrakis(tetrafluorophenyl)borate, a tetrakis(pentafluorophenyl)borate, a tetrakis(tetrafluoromethylphenyl)borate, a tetra(tolyl)borate, a tetra(xylyl)borate, a (tripheyl, pentafluorophenyl)borate, a [tris(pentafluorophenyl), phenyl]borate, and a tridecahydride-7,8-dicarbaundecaborate, with the tetrakis(pentafluorophenyl)borate being preferred.

The boron anion may be used as an ionic compound combined with cation. Examples of the cation include a carbonium cation, an oxonium cation, an ammonium cation, an amine cation, a phosphonium cation, a cycloheptatrienyl cation, and a ferrocenium cation containing a transition metal. Examples of the carbonium cation include trisubstituted carbonium cations such as a triphenylcarbonium cation and a tri(substituted phenyl)carbonium cation, and more specifically, an example of the tri(substituted phenyl)carbonium cation includes a tri(methylphenyl)carbonium cation. Examples of the amine cation include: trialkylammonium cations such as a trimethylammonium cation, a triethylammonium cation, a tripropylammonium cation, and a tributylammonium cation; N,N-dialkylanilinium cations such as a N,N-dimethylanilinium cation, a N,N-diethylanilinium cation, and a N,N-2,4,6-pentamethylanilinium cation; and dialkylammonium cations such as a diisopropylammonium cation and a dicyclohexylammonium cation. Specific examples of the phosphonium cation include triarylphosphonium cations such as a triphenylphosphonium cation, a tri(methylphenyl)phosphonium cation, and a tri(dimethylphenyl)phosphonium cation. Of those cations, the N,N-dialkylanilinium cations or the carbonium cations are preferred, and the N,N-dialkylanilinium cations are particularly preferred. Therefore, preferred examples of the ionic compound include a N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate and a triphenylcarbonium tetrakis(pentafluorophenyl)borate. The content of the ionic compound including a boron anion and a cation may preferably be added by 0.1-fold mol to 10-fold mol, and more preferably by about 1-fold mol, with respect to the metallocene-based composite catalyst.

Preferred examples of the co-catalyst that can be contained in the third polymerization catalyst composition may include an organic aluminum compound represented by the AlR²⁵R²⁶R²⁷, and also include aluminoxanes. The aluminoxane is similar to those described in the first polymerization catalyst composition and in the second polymerization catalyst composition.

In the case of using the polymerization catalyst or the polymerization catalyst composition described above in a method of manufacturing the copolymer according to the present invention, the method may be carried out similarly to a conventional method of manufacturing a copolymer through polymerization reaction using the coordination ion polymerization catalyst. Here, in the case of carrying out the method of manufacturing the copolymer of the present invention using the polymerization catalyst composition, the method can be performed in either one of the following manners. That is, for example, (1) the components forming the polymerization catalyst composition may be separately provided in the polymerization reaction system including, as monomers, a conjugated diene compound and a conjugated olefin, to thereby prepare the polymerization catalyst composition in the reaction system, or (2) the polymerization catalyst composition prepared in advance may be provided into the polymerization reaction system. Further, the method of (2) also includes providing the metallocene complex (active species) activated by the co-catalyst. The amount of the metallocene complex to be contained in the polymerization catalyst composition is preferably set to fall within a range of 0.0001-fold mol to 0.01-fold mol with respect to the total amount of the conjugate diene compound and the non-conjugated olefin.

Further, in the method of manufacturing the copolymer according to the present invention, a terminator such as ethanol and isopropanol may be used to stop the polymerization.

Further, the polymerization reaction may preferably be performed in an inert gas atmosphere, and preferably in nitrogen or argon atmosphere. The polymerization temperature of the polymerization reaction is not particularly limited, and preferably in a range of, for example, −100° C. to 200° C., and may also be set to temperatures around room temperature. An increase in polymerization temperature may reduce the cis-1,4-selectivity in the polymerization reaction. The polymerization reaction is preferably performed under pressure in a range of 0.1 MPa to 10 MPa so as to allow a conjugated diene compound and a non-conjugated olefin to be sufficiently introduced into the polymerization system. Further, the reaction time of the polymerization reaction is not particularly limited, and may preferably be in a range of, for example, 1 second to 10 days, which may be selected as appropriate depending on the conditions such as the type of the monomers to be polymerized, the type of the catalyst, and the polymerization temperature.

Further, according to the method of manufacturing the copolymer of the present invention, in polymerizing a conjugated diene compound and a non-conjugated olefin, the concentration of the conjugated diene compound (mol/L) and the concentration of the non-conjugated olefin (mol/L) at the start of copolymerization preferably satisfy the following relation:

the concentration of the non-conjugated olefin/the concentration of

the conjugated diene compound ≧1.0; further preferably satisfy the following relation:

the concentration of the non-conjugated olefin/the concentration of

the conjugated diene compound ≧1.3; and still further preferably satisfy the following relation:

the concentration of the non-conjugated olefin/the concentration of the conjugated diene compound ≧1.7.

The ratio of the concentration of the non-conjugated olefin to the concentration of the conjugated diene compound is defined to be at least 1, to thereby efficiently introduce the non-conjugated olefin into the reaction mixture.

In the case of polymerizing a conjugated diene compound with a non-conjugated olefin in the presence of the polymerization catalyst and the third polymerization catalyst composition, the monomer units of the conjugated diene compound and the non-conjugated olefin are irregularly arranged to form a random sequence, which makes it possible to form a tapered copolymer even without using the aforementioned method of introducing the conjugated diene compound in the presence of the non-conjugated olefin.

(Rubber Composition)

The rubber composition of the present invention is not particularly limited as long as the copolymer of the present invention is contained, and may be selected as appropriate depending on the application thereof. The rubber composition preferably contains rubber components other than the copolymer of the present invention, such as an inorganic filler, a carbon black, and a crosslinking agent.

<Copolymer>

The content of the copolymer of the present invention in the rubber components is not particularly limited, and may be selected as appropriate depending on the application thereof. The preferred content of the copolymer is at least 3 mass %.

The content of the copolymer in the rubber components falling short of 3 mass % may diminish the effect of the present invention or develop no effect at all.

<Rubber Components>

The rubber components are not particularly limited and may be selected as appropriate depending on the application thereof. Examples thereof include: the copolymer of the present invention, natural rubber, various types of butadiene rubber, various types of styrene-butadiene copolymer rubber, isoprene rubber, butyl rubber, a bromide of a copolymer of isobutylene and p-methylstyrene, halogenated butyl rubber, acrylonitrile-butadiene rubber, chloroprene rubber, ethylene-propylene copolymer rubber, ethylene-propylene-diene copolymer rubber, styrene-isoprene copolymer rubber, styrene-isoprene-butadiene copolymer rubber, isoprene-butadiene copolymer rubber, chlorosulfonated polyethylene rubber, acrylic rubber, epichlorohydrin rubber, polysulfide rubber, silicone rubber, fluororubber, and urethane rubber. These rubber components may be used alone or in combination of two or more.

The rubber composition may be mixed with a reinforcing filler as necessary. Examples of the reinforcing filler include a carbon black and an inorganic filler, and preferably at least one selected from the carbon black and the inorganic filler.

<Inorganic Filler>

The inorganic filler is not particularly limited and may be selected as appropriate depending on the application thereof. Examples thereof include silica, aluminum hydroxide, clay, alumina, talc, mica, kaolin, glass balloon, glass beads, calcium carbonate, magnesium carbonate, magnesium hydroxide, magnesium oxide, titanium oxide, potassium titanate, and barium sulfate. These rubber components may be used alone or in combination of two or more. In using an inorganic filler, a silane coupling agent may also be used as appropriate.

The content of the reinforcing filler is not particularly limited and may be selected as appropriate depending on the application thereof. The preferred content thereof is 5 parts by mass to 200 parts by mass with respect to 100 parts by mass of the rubber component.

The reinforcing filler added by less than 5 parts by mass in content may show little effect of the addition thereof, whereas the content exceeding 200 parts by mass tends to hinder the reinforcing filler to be mixed into the rubber component, which may impairs the performance of the rubber composition.

<Crosslinking Agent>

The crosslinking agent is not particularly limited and may be selected as appropriate depending on the application thereof. Examples thereof include a sulfur-containing crosslinking agent, an organic peroxide-containing crosslinking agent, an inorganic crosslinking agent, a polyamine crosslinking agent, a resin crosslinking agent, a sulfur compound-based crosslinking agent, an oxime-nitrosamine-based crosslinking agent, and sulfur, with the sulfur-containing crosslinking agent being more preferred as the rubber composition for a tire.

The content of the crosslinking agent is not particularly limited and may be selected as appropriate depending on the application thereof. The preferred content thereof is 0.1 parts by mass to 20 parts by mass with respect to 100 parts by mass of the rubber component.

The crosslinking agent added by less than 0.1 parts by mass in content may hardly develop crosslinking, whereas the content exceeding 20 parts by mass tends to develop cros slinking by part of the crosslinking agent during the mixing, or to impair the physical property of the vulcanizate.

<Other Components>

Other than the above, a vulcanization accelerator may also be contained. Examples of compounds that can be used as the vulcanization accelerator include: guanidine-based compounds, aldehyde-amine-based compounds, aldehyde-ammonia-based compounds, thiazole-based compounds, sulfenamide-based compounds, thiourea-based compounds, thiuram-based compounds, dethiocarbamate-based compounds, and xanthate-based compounds.

Further, if necessary, any known agent such as a reinforcing agent, a softening agent, a co-agent, a colorant, a flame retardant, a lubricant, a foaming agent, a plasticizer, a processing aid, an antioxidant, an age resister, an anti-scorch agent, an ultraviolet rays protecting agent, an antistatic agent, a color protecting agent, and other compounding agent may be used according to the purpose of use thereof.

(Crosslinked Rubber Composition)

The crosslinked rubber composition according to the present invention is not particularly limited as long as being obtained by crosslinking the rubber composition of the present invention, and may be selected as appropriate depending on the application thereof.

The conditions of the crosslinking are not particularly limited and may be selected as appropriate depending on the application thereof. The preferred conditions of temperature and heating time for the crosslinking may preferably be in a range of 120° C. to 200° C. for 1 minute to 900 minutes.

(Tire)

A tire of the present invention is not particularly limited as long as being manufactured by using the rubber composition of the present invention or the crosslinked rubber composition of the present invention, and may be selected as appropriate depending on the application thereof. The rubber composition of the present invention or the crosslinked rubber composition of the present invention may be applied, for example, to a tread, a base tread, a sidewall, a side reinforcing rubber, and a bead filler of a tire, without being limited thereto.

The tire can be manufactured by a conventional method. For example, a carcass layer, a belt layer, a tread layer, which are composed of unvulcanized rubber, and other members used for the production of usual tires are successively laminated on a tire molding drum, then the drum is withdrawn to obtain a green tire. Thereafter, the green tire is heated and vulcanized in accordance with an ordinary method, to thereby obtain a desired tire.

(Applications Other than Tires)

The rubber composition of the present invention or the crosslinked rubber composition of the present invention may be used for other applications than tires, such as anti-vibration rubber, seismic isolation rubber, a belt (conveyor belt), a rubber crawler, various types of hoses, and moran.

EXAMPLES

In the following, the invention of the present invention is described with reference to Examples. However, the present invention is no way limited to the following Examples.

Example 1

Ethylene was introduced at 0.8 MPa into a 400 mL pressure-resistant grass reactor that had been sufficiently dried, and then 160 mL of a toluene solution containing 9.14 g (0.17 mol) of 1,3-butadiene was added thereto. Meanwhile, in a glovebox under a nitrogen atmosphere, 28.5 μmol of bis(2-phenylindenyl)gadolinium bis(dimethylsilylamide) [(2-PhC₉H₆)₂GdN(SiHMe₂)₂], 34.2 μmol of dimethylanilinium tetrakis(pentafluorophenyl)borate [Me₂NHPhB(C₆F₅)₄], and 1.43 mmol of diisobutylaluminum hydride were provided in a glass container, which was dissolved into 8 mL of toluene, to thereby obtain a catalyst solution. After that, the catalyst solution was taken out from the glovebox and added by 28.2 μmol of gadolinium equivalent to the monomer solution, which was then subjected to polymerization at room temperature for 60 minutes. Thereafter, 60 mL of a toluene solution containing 9.14 g (0.17 mol) of 1,3-butadiene was newly added at a rate of 1.0 ml/min while reducing the introduction pressure of ethylene at a rate of 0.1 MPa/min, and then polymerization was further performed for another 60 minutes. After the polymerization, 1 mL of an isopropanol solution containing, by 5 mass %, 2,2′-methylene-bis(4-ethyl-6-t-butylphenol) (NS-5), was added to stop the reaction. Then, a large amount of methanol was further added to isolate the copolymer, and the copolymer was vacuum dried at 70° C. to obtain a copolymer A. The yield of the copolymer A thus obtained was 16.30 g. Here, FIG. 1 is a ¹³C-NMR spectrum chart of the copolymer A, and FIG. 2 shows a DSC curve of the copolymer A.

(Synthesis of (2-PhC₉H₆)₂Nd(β-Me)₂AlMe₂)

Under a nitrogen atmosphere, 4.5 mL of a toluene solution containing AlMe₃ (9.0 mmol)(manufactured by Aldrich) was slowly delivered by drops into 50 mL of a toluene solution containing 2.00 g (3.03 mmol) of (2-PhC₉H₆)₂Nd[N(SiHMe₂)₂], which was stirred at room temperature for 16 hours. Thereafter, the toluene was vacuum distilled and the residue was washed for several times by hexane, to thereby obtain (2-PhC₉H₆)₂Nd(μ-Me)₂AlMe₂ (1.60 g, 86%) in the form of a green powder. The structure of the metallocene-based composite catalyst thus obtained was studied by ¹H-NMR. Here, the measurement by ¹H-NMR was performed at 20° C. using a toluene-d₈ as a solution.

Example 2

A toluene solution of 300 mL containing 9.25 g (0.171 mol) of 1,3-butadiene was added to a 400 mL pressure-resistant grass reactor that had been sufficiently dried, and then ethylene was introduced thereto at 0.8 MPa. Meanwhile, in a glovebox under a nitrogen atmosphere, 204.0 μmol of dimethylaluminum(μ-dimethyl)bis(2-phenylindenyl)neodymium [(2-PhC₉H₆)₂Nd(μ-Me)₂AlMe₂] and 195.0 μmol of triphenylcarbonium tetrakis(pentafluorophenyl)borate [Ph₃CB(C₆F₅)₄] were provided in a glass container, and dissolved into 20 mL of toluene, to thereby obtain a catalyst solution. After that, the catalyst solution was taken out from the glovebox, and added to the monomer solution, which was then subjected to polymerization at room temperature for 150 minutes. After the polymerization, 1 mL of an isopropanol solution containing, by 5 mass %, 2,2′-methylene-bis(4-ethyl-6-t-butylphenol) (NS-5), was added to stop the reaction. Then, a large amount of methanol was further added to isolate the copolymer, and the copolymer was vacuum dried at 70° C. to obtain a copolymer B. The yield of the copolymer B thus obtained was 14.25 g. Here, FIG. 3 is a ¹³C-NMR spectrum chart of the copolymer B, and FIG. 4 shows a DSC curve of the copolymer B.

Example 3

An experiment was performed similarly to Example 1 except that the ethylene was first introduced at a pressure of 1.5 MPa, to thereby obtain a copolymer C. The yield of the copolymer C thus obtained was 17.55 g. FIG. 5 shows a DSC curve of the copolymer C.

Comparative Example 1

Butadiene rubber (BR01, manufactured by JSR) was prepared as a sample of Comparative Example.

Comparative Example 2

A toluene solution of 700 mL containing 28.0 g (0.52 mol) of 1,3-butadiene was added to a 2 L stainless reactor that had been sufficiently dried, and then ethylene was introduced thereto at 0.8 MPa. Meanwhile, in a glovebox under a nitrogen atmosphere, 400.0 μmol of dimethylaluminum(μ-dimethyl)bis(2-phenylindenyl)neodymium [(2-PhC₉H₆)₂Nd(μ-Me)₂AlMe₂] and 200.0 μmol of triphenylcarbonium tetrakis(pentafluorophenyl)borate [Ph₃CB(C₆F₅)₄] were provided in a glass container, and dissolved into 80 mL of toluene, to thereby obtain a catalyst solution. After that, the catalyst solution was taken out from the glovebox, and the catalyst solution was added by 390.0 μmol of neodymium equivalent to the monomer solution, which was then subjected to polymerization at room temperature for 120 minutes. After the polymerization, 1 mL of an isopropanol solution containing, by 5 mass %, 2,2′-methylene-bis(4-ethyl-6-t-butylphenol) (NS-5), was added to stop the reaction. Then, a large amount of methanol was further added to isolate the copolymer, and the copolymer was vacuum dried at 70° C. to obtain a copolymer D (random copolymer). The yield of the copolymer D thus obtained was 18.00 g. FIG. 6 shows a DSC curve of the copolymer D.

Comparative Example 3

As illustrated in Preparation 1 of JP 2000-86857 A, a toluene solution (manufactured by Tosoh Akzo Corporation) containing 26.0 g of toluene and 6.7 mmol of methylaluminoxane were provided in a sealed pressure tight glass ampoule having an inner capacity of 150 mL in a nitrogen atmosphere. A toluene solution containing 0.0067 mmol of 2-methoxycarbonyl methylcyclopentadienyl trichlorotitanium (MeO(CO)CH₂CpTiCl₃) (TiES) was delivered by drops into the ampoule which was held at aging temperature (25° C.) over an aging time of 5 minutes. Thereafter, the temperature was reduced to −25° C., and a solution containing 2.0 g of butadiene and 6.0 g of toluene was added, which was then subjected to polymerization at this temperature for 30 minutes. Subsequently, ethylene was supplied into the container to give a pressure of 5 kgf/cm², and the reaction was carried out for about 1 hour. Thereafter, a small amount of an acidic methanol solution was added to stop the polymerization reaction, and then the polymerization solution was poured into a large amount of acidic methanol, so that a precipitated white solid was collected by filtration and dried to obtain a copolymer E. FIG. 7 shows a DSC curve of the copolymer E.

The copolymers A to C of Examples 1 to 3, the butadiene rubber of Comparative Example 1, and the copolymers D and E of Comparative Examples 2 to 3 were each subjected to measurement and evaluation by the following method so as to investigate the microstructure, the ethylene content, the weight-average molecular weight (Mw), the molecular weight distribution (Mw/Mn), and the DSC curve.

(1) Microstructure (1,2-vinyl bond content, cis-1,4 bond content)

The microstructure (1,2-vinyl bond content) of the butadiene unit in the copolymer is determined from an integral ratio of 1,2-vinyl bond component (5.0 ppm to 5.1 ppm) to a butadiene bond component (5 ppm to 5.6 ppm) of the whole, based on ¹H-NMR spectrum (100° C., d-tetrachloroethane standard: 6 ppm), and the microstructure (cis-1,4 bond content) of the butadiene unit in the copolymer is determined from an integral ratio of cis-1,4 bond component (26.5 ppm to 27.5 ppm) to a butadiene bond component (26.5 ppm to 27.5 ppm+31.5 ppm to 32.5 ppm) of the whole, based on ¹³C-NMR spectrum (100° C., d-tetrachloroethane standard: 73.8 ppm). The calculated values of the 1,2-vinyl bond content (%) and cis-1,4 bond content (%) are shown in Table 1.

It should be noted that the measurement results shown in FIGS. 1 and 3 were obtained by using, as measurement samples, rubber components obtained by immersing each copolymer in a large amount of tetrahydrofuran for 48 hours so as to remove all the butadiene homopolymer and a single polymer of ethylene-butadiene random copolymer dissolved in the tetrahydrofuran and then by drying the copolymer, in order to circumvent the effect to be produced by the mixture of the butadiene homopolymer or a homopolymer of the ethylene-butadiene random copolymer.

(2) Ethylene Content

The content (mol %) of the ethylene unit in the copolymer is determined from an integral ratio of an ethylene bond component (28.5 ppm to 30.0 ppm) of the whole to a butadiene bond component (26.5 ppm to 27.5 ppm+31.5 ppm to 32.5 ppm) of the whole, based on ¹³C-NMR spectrum (100° C., d-tetrachloroethane standard: 7.38 ppm). The content (mol %) of the ethylene unit is shown in Table 1.

(3) Weight-Average Molecular Weight (Mw) and Molecular Weight Distribution (Mw/Mn)

A polystyrene equivalent weight-average molecular weight (MW) and a molecular weight distribution (Mw/Mn) of each copolymer were obtained through gel permeation chromatography [GPC: HLC-8121GPC/HT (manufactured by Tosoh Corporation), column: two of GMH_(HR)-H(S)HT (manufactured by Tosoh Corporation), detector: a differential refractometer (RI)], using monodisperse polystyrene as a reference. The measurement temperature was 140° C.

(4) DSC curve

A DSC curve of each copolymer was obtained by differential scanning calorimetry (DSC) according to JIS K7121-1987. In the measurement, used as measurement samples were rubber components obtained by immersing each copolymer in a large amount of tetrahydrofuran for 48 hours so as to remove all the butadiene homopolymer and a single polymer of ethylene-butadiene random copolymer dissolved in the tetrahydrofuran and then by drying the copolymer, in order to eliminate the effect to be produced by the mixture of the butadiene homopolymer or a homopolymer of the ethylene-butadiene random copolymer.

TABLE 1 Comparative Comparative Comparative Example 1 Example 2 Example 3 Example 1 Example 2 Example 3 Copolymer A B C butadiene D E rubber Mw 295 102 247 454 263 230 (×10³) Mw/Mn 2.50 1.50 1.93 3.45 1.58 1.32 Cis-1,4 Bond 98 84 97 97 91 92 Content (%) Ethylene Content 15 34 37 — 15 16 (mol %) 1,2-adduct Content 0.8 2.4 2.4 2.2 2.1 6.0 (mol %)

Further, the sequence distribution of the copolymer A was analyzed by applying ozonolysis-GPC measurements disclosed in a document (“Polymer Preprints, Japan, Vol. 42, No. 4, pp. 1347”). A polystyrene equivalent weight-average molecular weight (MW) and molecular weight distribution (Mw/Mn) of each copolymer were obtained through gel permeation chromatography [GPC: HLC-8121GPC/HT (manufactured by Tosoh Corporation), column: two of GPC HT-803 (manufactured by Showa Denko K.K.), detector: differential refractometer (RI)], using monodisperse polystyrene as a reference, at measurement temperature of 140° C.]. The result showed that the total ethylene component contained 30 mass % to 80 mass % of a block ethylene component, that is, polyethylene component having a number-average molecular weight (Mn) of 1,000 or more, while containing 20 mass % or less of a long-chain polyethylene component having a number-average molecular weight (Mn) of 40,000 or more.

Further, the ¹³C-NMR spectrum chart of the copolymer A of FIG. 1 shows, as peaks derived from ethylene in a range of 27.5 ppm to 33 ppm, a peak observed other than a peak at 29.4 ppm indicating at least four-chained ethylene (indicating a block sequence), which means that ethylene units having three or less chains are also arranged in butadiene, and therefore the measurement yielded a result indicating the formation of a random sequence.

The DSC curve of the copolymer A of FIG. 2 shows, with respect to a total endothermic peak area derived from the ethylene chain in a temperature range of 40° C. to 140° C., a broad endothermic peak was observed in a temperature range of 40° C. to 120° C., indicating a random sequence being formed which includes randomly-arranged monomer units of butadiene and ethylene (including a block of low molecular weight), other than an endothermic peak in a temperature range of 120° C. or above derived from the crystallization temperature of the long-chain block sequence including monomer units of ethylene.

The aforementioned measurement revealed that the copolymer A was a tapered copolymer of 1,3-butadiene and ethylene.

It was similarly confirmed that the copolymers B and C were tapered copolymers of 1,3-butadiene and ethylene.

In the DSC curve of the copolymer D of FIG. 6, a crystallization temperature of 120° C. or above to be derived from the block sequence including monomer units of ethylene could not be observed in a temperature range of 40° C. to 140° C. Further, the ozonolysis-GPC measurements of the copolymer D showed that the total ethylene component contained 30 mass % or less of a block ethylene component, that is, polyethylene component having a number-average molecular weight (Mn) of 1,000 or more, while containing 1 mass % or less of a long-chain polyethylene component having a number-average molecular weight (Mn) of 40,000 or less, and thus the copolymer D was a random copolymer.

In the DSC curve of the copolymer E of FIG. 7, crystallization temperatures to be derived from a random sequence including a monomer units of ethylene were hardly observed in a temperature range of 40° C. to 120° C. Further, the ozonolysis-GPC measurements of the copolymer E showed that the total ethylene component contained 90 mass % or more of a block ethylene component, that is, polyethylene component having a number-average molecular weight (Mn) of 1,000 or more, while containing 70 mass % or more of a long-chain polyethylene component having a number-average molecular weight (Mn) of 40,000 or less, and thus the copolymer E was found to be a block copolymer.

The polymer should not excessively contain the block components or the random components, or high molecular weight polyethylene. Otherwise, the excellent performance of the present invention cannot be obtained.

As Examples 1, 3 and Comparative Examples 1 to 3, the rubber compositions formulated as shown in Table 2 were prepared, which were vulcanized at 160° C. for 20 minutes. The vulcanized rubber compositions thus obtained were subjected to measurements of heat resistance and flex fatigue resistance, according to the following method.

TABLE 2 parts by mass copolymer 100 stearic acid 2 carbon black (FEF class) 50 age resistor *1 1 zinc oxide 3 co-agent CZ-G *2 0.4 co-agent DM-P *3 0.2 sulfur 1.4 *1: N-(1,3-dimethylbutyl)-N′-p-phenylenediamine (NOCRAC 6C), manufactured by OUCHI SHINKO CHEMICAL INDUSTRIAL CO., LTD. *2: N-cyclohexyl-2-benzothiazolesulfenamide (NOCCELER CZ-G), manufactured by OUCHI SHINKO CHEMICAL INDUSTRIAL CO., LTD. *3: dibenzothiazyl disulfide (NOCCELER DM-P), manufactured by OUCHI SHINKO CHEMICAL INDUSTRIAL CO., LTD.

<<Heat Resistance Test>>

Sample test pieces were each caused to deteriorate in an oven of 100° C. for 48 hours. Then, each sample taken out from the oven was subjected to tension test according to JIS K 6251 at room temperature, to thereby obtain the tensile stress at 300% strain (Md 300%). Table 3 shows the result thereof as Md variation (%), which are indexed with a score of 100 representing Md 300% obtained by tension test performed for samples with no thermal degradation. The smaller variation (%) shows more excellent heat resistance.

<<Flex Fatigue Resistance Test>>

The crack growth was examined in a flexing crack test according to JIS-K6260 using a DeMattia Flex Fatigue Tester. A predetermined crack was given and the number of bendings it took to grow the crack by 1 mm was counted for each sample. The results thereof are shown as being indexed with a score of 100 representing Comparative Example 1. As to the butadiene compound, the results obtained for Comparative Examples and Examples are shown as being indexed with a score of 100 representing Comparative Example 1. The larger index value shows more excellent flex fatigue resistance. In Table 3, “>200” means that the crack showed no growth of 1 mm despite the repetitive fatigue applied twice as many as those applied to Comparative Example 1.

TABLE 3 Comparative Comparative Comparative Example 1 Example 2 Example 3 Example 1 Example 2 Example 3 Copolymer A B C butadiene D E rubber Mw 295 102 247 454 263 230 (×10³) Mw/Mn 2.50 1.50 1.93 3.45 1.58 1.32 Cis-1,4 Bond 98 84 97 97 91 92 Content (%) Ethylene Content 15 34 37 — 15 16 (mol %) Flex Fatigue >200 — >200 100 112 148 Resistance Heat Resistance 134 — 131 158 125 155 (Md variation (%))

INDUSTRIAL APPLICABILITY

The copolymer of the present invention can be used generally for elastomer products, in particular, tire members. 

1. A copolymer of a conjugated diene compound and a non-conjugated olefin, comprising a tapered copolymer including: at least one of a block sequence including monomer units of the conjugated diene compound and a block sequence including monomer units of the non-conjugated olefin; and a random sequence including randomly arranged monomer units of the conjugated diene compound and monomer units of the non-conjugated olefin.
 2. The copolymer according to claim 1, wherein the conjugated diene compound unit has a cis-1,4 bond content of at least 30%.
 3. The copolymer according to claim 2, wherein the conjugated diene compound unit has a cis-1,4 bond content of at least 50%.
 4. The copolymer according to claim 1, wherein the conjugated diene compound unit has 1,2 adducts (including 3,4 adducts) content of 5% or less.
 5. The copolymer according to claim 1, wherein the non-conjugated olefin is contained over 0 mol % to 50 mol % or less.
 6. The copolymer according to claim 5, wherein the non-conjugated olefin is contained over 0 mol % to 40 mol % or less.
 7. The copolymer according to claim 1, wherein the tapered copolymer has any one of the structures of (A-B)_(X), A-(B-A)_(X) and B-(A-B)_(X), wherein A represents a random sequence including randomly arranged monomer units of the conjugated diene compound and the non-conjugated olefin, B represents one of a block sequence including monomer units of the conjugated diene compound and a block sequence including monomer units of the non-conjugated olefin, and x represents an integer of at least
 1. 8. The copolymer according to claim 1, comprising a copolymer having a polystyrene-equivalent average-weight molecular weight of 10,000 to 10,000,000.
 9. The copolymer according to claim 1, comprising a copolymer having a molecular weight distribution (Mw/Mn) of 10 or less.
 10. The copolymer according to claim 1, wherein the non-conjugated olefin is an acyclic olefin.
 11. The copolymer according to claim 1, wherein the non-conjugated olefin has 2 to 10 carbon atoms.
 12. The copolymer according to claim 10, wherein the non-conjugated olefin is at least one selected from a group consisting of ethylene, propylene, and 1-butene.
 13. The copolymer according to claim 12, wherein the non-conjugated olefin is ethylene.
 14. The copolymer according to claim 1, wherein the conjugated diene compound is at least one selected from a group consisting of 1,3-butadiene and isoprene.
 15. A rubber composition comprising the copolymer according to claim
 1. 16. The rubber composition according to claim 15 comprising the copolymer in a rubber component.
 17. The rubber composition according to claim 15, comprising, with respect to 100 parts by mass of the rubber component, a reinforcing filler by 5 parts by mass to 200 parts by mass and a crosslinking agent by 0.1 parts by mass to 20 parts by mass.
 18. A crosslinked rubber composition obtained by crosslinking the rubber composition according to claim
 15. 19. A tire manufactured by using the rubber composition according to claim
 15. 20. A tire manufactured by using the crosslinked rubber composition according to claim
 18. 